1993 DODGE TRUCK Service Repair Manual

11 - 26
EXHAUST SYSTEM
AND
INTAKE MANIFOLD

• condenser and sealing plate assembly away from
the charge air cooler (intercooler).

Fig.
34 Condenser and
Charge
Air Cooler (Intercooler)
(4) Remove the inlet and outlet ducts from the
charge air cooler (intercooler)—(Fig. 35).
(5) Remove the charge air cooler (intercooler) bolts.
Pivot the charge air cooler (intercooler) forward and
up to remove.

INSTALLATION
(1) Position the charge air cooler (inter­
cooler)—(Fig. 34). Install the bolts and tighten to 2
N-m (17 in. lbs.) torque.
Fig.
35 Charge Air Cooler (Intercooler) Ducts
(2) Install the inlet and outlet ducts to the charge
air cooler (intercooler)—(Fig. 35). With the clamps in
position, tighten the clamp nut to 8 N-m (72 in. lbs.)
torque.
(3) If the vehicle is equipped with air conditioning,
install the condenser as follows: (a) Position the condenser and sealing plate as­
sembly onto the charge air cooler (intercooler)

studs.
Install the nuts and tighten.
(b) Connect the halves of the sealing plate (Fig.

34).
Install the bolt and tighten. (c) Charge the air conditioning system (refer to
Group 24, Heating and Air Conditioning for the
proper procedures).
(4) Install the front support bracket (Fig. 34). In­
stall and tighten the bolts. (5) Install the grille (refer to Group 23, Body for
the proper procedure).

•

EXHAUST SYSTEM
AND
INTAKE MANIFOLD
11-27
SPECIFICATIONS

TURBOCHARGER SPECIFICATIONS

COMPONENT
DIMENSIONS

Air Intake Restrictions
635
mm Water (25 in. Water) Max.
Turbo Radial Clearance
0.300-0.460
mm
(0.012-0.018
inch)
Turbo Rotor Assembly End Play Before S/N 840638 0.102-0.152 mm (0.004-0.006 inch)
S/N
840638
AND AFTER .
0.026-0.076
mm
(0.001-0.003
inch)
Turbo Shaft Bearing Diameter
10.97 (0.432
inch)

J9111-26

11
- 28
EXHAUST
SYSTEM
AND
INTAKE MANIFOLD

•
DESCRIPTION

TORQUE
DESCRIPTION

TORQUE

Adjusting
Strop
Bolt
23
N-m
(200 in.
lbs.)

Air Heater Power Supply Nuts 14 N-m (10
ft.
lbs.) Cab
Heater Supply/Return Line Nuts 24
N-m
(18
ft.
lbs.)

Catalytic
Converter-to-Muffler Clamp Nuts 43 N-m (32 ft. lbs.)
Exhaust Manifold-to-Cylinder
Head
Bolts
(5.9L Diesel) 43 N-m (32
ft.
lbs.)
Exhaust Manifold-to-Cylinder
Head Bolts/Nuts 34
N-m (25
ft. lbs.)
Exhaust Pipe-to-Catalytic
Converter Clamp Nuts 43 N-m (32 ft. lbs.)
Exhaust Pipe-to-Exhaust

Manifold
Bolts/Nuts 26 N-m (19 ft. lbs.)
Fuel Heater Ground Bolt . 12 N-m (110 in. lbs.)
Fuel Line Nuts 24 N-m (18ft. lbs.)
Generator Mounting Bolt 41 N-m (30 ft. lbs.) Intake ManiFolcf Capbolts Refer to Procedure
in
Service Manual.
Intake Manifold Cover Bolts 24 N-m (18 ft. lbs.)
Intercooler Attaching Bolts............................. 2 N-m (17 in. lbs.) Intercooler Duct Clamp Nuts 8 N-m (72 in. lbs.) Muffler-to-Tail Pipe Clamp Nuts 43 N-m (32 ft. lbs.)
Plenum Pan Bolts (3.9L
& 5.2L)
1st Step 2.7 N-m (24 in. lbs.)
2nd Step 5.4 N-m (48 in. lbs.)
3rd Step 9.5 N-m (84 in. lbs.)
Throttle Body
(MPI)
Bolts 23 N-m (200 in. lbs.)
Throttle Control Bracket Mounting Bolts 24 N-m (18 ft. lbs.)
Thrust Bearing Torx Bolts............................ 4.5 N-m (40 in. lbs.)
Turbocharger Bearing Housing/ Diffuser Bolts 5.7 N-m (50 in. lbs.)
Turbocharger Bearing Housing/ Turbine Housing Bolts 11.3 N-m (100 in. lbs.)
Turbocharger Impeller Nut 14 N-m (129 in. lbs.) Turbocharger Mounting Nuts 32 N-m (24 ft. lbs.)
Turbocharger Oil Drain Tube Bolts... 24 N-m (18 ft. lbs.) Turbocharger Oil Supply Line Fitting Nut.. 15 N-m (11 ft. lbs.)
Turbocharger V-Band Clamp 8.5 N-m (75 in. lbs.)

J9311-12

TORQUE
SPECIFICATIONS

• •
•
FRAME AND BUMPERS 13 - 1
CONTENTS

page page

ATTACHED COMPONENTS . B B. B. B . 30 FRAME 20 BUMPERS 1 SNOW PLOW 3
BUMPERS
FRONT BUMPER

REMOVAL/DISASSEMBLY
(1) Support bumper.
(2) Remove bumper nuts and bolts from the
bumper brackets.
(3) Remove support and bumper from vehicle. (4) Remove nuts and bolts, and bumper brackets
from frame rails.
INSTALLATION (1) Position the bumper brackets on the frame

rails.
Install bolts and nuts. Tighten to 68 Nnn (50 ft. lbs) torque.
(2) Position and support the bumper at the front of
the vehicle. Align bumper bolt holes with bracket

holes.

(3) Insert bumper bolts in brackets. Install nuts.
Verify the bumper is aligned with grille and fenders.
Tighten nuts to 41 N*m (30 ft. lbs.) torque.
REAR BUMPER TEMPORARY BUMPER

REMOVAL
(1) Support bumper.
(2) Remove bumper bracket nuts and bolts from
the frame rails.
(3) Remove support and remove bumper from the
vehicle.
STANDARD BUMPER

REMOVAL
(1) Support the bumper,
(2) Remove bumper nuts and bolts from the frame
side rails and bumper brackets.
(3) Remove support and bumper from vehicle.
(4) Remove nuts and bolts, and remove bumper
brackets from bumper.
BOLT

FRAME

RAIL

NUT-LOCK

NUT

BUMPER

BRACKET
J9123-326

Fig.
1 Front
Bumper
INSTALLATION

(1) Position the bumper brackets on the bumper
with the bolt holes aligned. Install the bolts and
nuts.
Tighten to 41 N«m (30 ft. lbs.) torque.
(2) Position and support the bumper at the rear of
the vehicle. Align the bumper bracket bolt holes with
the frame side rail holes.
(3) Insert bumper bracket bolts in the brackets and
the frame side rails. Install nuts. Verify bumper is aligned with the rear corner panels. Tighten the nuts
to 68 N-m (50 ft. lbs.) torque.
(4) Remove the support from the bumper.
BUMPER FILLER PANEL-RAMCHARGER

REMOVAL
(1) Remove the filler panel screws from the rear
cross sill.

FRAME
AND
BUMPERS

13 - 2
FRAME
AND
BUMPERS

•
Fig. 2 Standard Rear Bumper
(2) Remove the filler panel from the rear cross sill
and rear bumper.
INSTALLATION

(1) Position the filler panel lip under the rear
bumper. Position the flange against the rear cross
sill.

(2) Align the filler panel flange screw holes with
the sill holes. Install the screws. Tighten the screws
until the heads are seated.

TO SILL
BUMPER J9123-361
Fig. 3 Bumper Filler Panel
STEP BUMPER

REMOVAL
(1) Remove the wire harness clip retainers. Discon­
nect the bulb sockets from each license plate lamp.
Detach the wire harness from the step bumper (Fig.

4).

(2) Support the step bumper.
(3) Remove the nuts and bolts that attach each
bumper support bracket and brace to the frame rails (Fig. 5). (4) Lower the bumper and remove as a unit.
(5) Remove the bracket and brace bolts to the
bumper. Remove the brackets and braces from the
bumper (Fig. 5).

INSTALLATION
(1) Attach brackets and braces to the bumper with
the bolts and nuts. Tighten the support bracket nuts
to 68 N*m (50 ft. lbs.) torque. Tighten the brace nuts
to 41 N»m (30 ft. lbs.) torque.
(2) Position step bumper assembly to the rear of
the vehicle.
(3) Align the support bracket and brace holes with
the holes in the frame rails. Install the bracket at­
taching bolts and nuts. (4) Ensure that the bumper is correctly aligned
with the cargo box rear corner panels. Tighten to 68 N«m (50 ft. lbs.) torque.
(5) Connect the license plate lamp bulb sockets to
the lamps. Attach the wire harness to the bumper
with the clip retainers (Fig. 4). (6) Remove the support from the bumper.

LOCATOR
LAMP
CLIP WIRE

BUMPER SCREW J9123429
Fig. 4 License Plate Lamp Wire Harness Fig. 5 Rear Step Bumper

•

FRAME
AND
BUMPERS
13 - 3
SNOW
PLOW

NDEX

page

Power
Angling Cylinder Service
16

Power
Unit
. . 13

Service
Information
3

Snow
Plow Control Module
17

Snow
Plow Frame
16

SERVICE
INFORMATION
A snow plow is optionally available for 4WD Ram
Truck and Ramcharger vehicles. The primary me­ chanical components are illustrated in Figure 1.

LIFT
ARM

RUNNERS
J9001-2
Fig.
1
Snow
Plow
Components
COMPONENT DESCRIPTION
The primary snow plow components are described
within the following list:
• Moldboard — Snow blade constructed from high
tensile steel
• Trip springs — Allow the moldboard to tilt for­
ward and slide over obstructions without losing the snow load
• Sector — Used for positioning the moldboard
• straight ahead or angling it to the right or left
page

Snow
Plow Malfunction
Diagnosis
and
Tests
4
Snow
Plow Pivot Bracket
16

Snow
Plow Wiring Diagrams
4

System
Description
and
Operation
3
• Sector shear pin — Self-locking pin that locks the moldboard in either a straight ahead or an an­
gled plowing position
If the blade impacts obstructions, the pin will
shear to protect the snow plow and the vehicle
from damage. The pin is not used with power angle plowing.
• Power angling cylinders — Enable the operator
to move the moldboard either straight ahead or to
the side
• Hinge pins — Allows the A-Frame to pivot up
and down. The pins act as attaching points.
• Cutting edge — Replaceable blade edge extends
the life of the blade • Runners — Adjustable runners retain the cutting
edge at the proper height
• Sno-Flo paint — Specially developed high-
• visibility, yellow paint provides fast, smooth snow-
rolling action • Hydraulic pump and motor (Electro-Touch ™)
— Hydraulically raises, lowers and angles the snow
plow
• A-frame — Provides the means for attaching the snow plow to the vehicle
• Lift arm — Raises and lowers the snow plow.

SYSTEM
DESCRIPTION
AND OPERATION HYDRAULIC CYLINDER
AND
MOTOR
The hydraulic cylinder and motor unit is designed
to raise, lower and angle the blade. The power unit is a high torque, 12-volt motor that
is coupled to a gear-type hydraulic pump. The toggle switches operate the solenoid valves.
The following components control the snow plow blade positioning: • Solenoid valves designated A,B, and C
• Mechanical hydraulic check valves
• Pilot check valve
• Crossover relief valve

SOLENOID
fELEGTRO'MEGHANIGALj VALVES
Three solenoid valves are used for snow plow con­
trol. Each valve is comprised of two components:
• Cartridge — Comprised of a valve and a solenoid.

13 - 4
FRAME
AND
BUMPERS

• • Coil — The electrical component that retracts the
cartridge solenoid.
With power applied, the solenoid retracts and pulls
the poppet valve into the OPEN position.
When power is turned off, the spring forces the so­
lenoid back to its normal, CLOSED position.

SOLENOID
VALVE
A The solenoid valve A cartridge contains a poppet
valve. This valve is normally de-energized in the CLOSED position. When closed, the valve retains
pressure in the lift cylinder. When it is energized (valve opened), it allows the fluid to flow from the
lift cylinder back to the reservoir. This enables the
plow blade to lower via gravity.
Solenoid valve A is designed to remain energized
(valve open) during plowing to provide a floating
blade position. This ensures that the plow blade is guided up-down by the surface deviations.

SOLENOID
VALVE
B The solenoid valve B cartridge contains a spool
valve. This valve is normally in the de-energized CLOSED position. This allows the fluid to flow to the
C solenoid. In the energized OPEN position, the fluid
is diverted to the lift cylinder. This causes the plow
blade to be raised.

SOLENOID
VALVE
C The solenoid valve C cartridge contains a spool
valve that is normally in the de-energized CLOSED
position. This allows the fluid to flow to the right- side power angling cylinder. This angles the blade to
the left. At the same time, it allows the fluid from
the retracting left-side power angling cylinder to re­
turn to the pump reservoir. Energizing the solenoid valve will route fluid to
the left side angling cylinder. This angles the plow
blade to the right. Also, the fluid is forced from the
retracting right side cylinder. It flows through the C cartridge valve and returns to the pump reservoir.
MECHANICAL HYDRAULIC VALVES The mechanical hydraulic valves all have the same
function: they control the direction of the hydraulic
fluid flow.

CHECK
VALVES
Check valves allow fluid to flow freely in one direc­
tion while preventing fluid from flowing in the oppo­ site direction.
A pump check valve is used to prevent fluid from
leaking back through the pump to the reservoir.
Two additional check valves are necessary because
solenoid valves B and C have some leakage.
One check valve is located between solenoid valve
B and the lift cylinder. It prevents fluid in the lift cylinder from leaking back through solenoid valve B.
If fluid leaks back, it could angle the blade to the
left. This would force fluid through solenoid valve C into the right side cylinder.
The other check valve is located between valve B
and valve C. It prevents fluid from being forced
through solenoid valve B.

PILOT CHECK VALVE
A pilot check valve has a piston in addition to a
ball seat and spring. A pilot check valve is located
between solenoid valve C and the reservoir. It has two functions:
• Prevents the hydraulic fluid in either angling cyl­inder from leaking back to the reservoir.
• Allows the hydraulic fluid from a retracting an­
gling cylinder to return to the reservoir. The valve action is done by fluid moving the pis­
ton, which forces the check ball off its seat.

CROSSOVER
RELIEF VALVE
This valve protects against damage by a sudden
impact against the end of the blade. This will cause
high hydraulic pressure to accumulate in one of the angling cylinders. The hydraulic pressure increases enough to open
the crossover relief valve. The valve allows the
highly pressurized hydraulic fluid to flow to the other cylinder. This cushions the impact and changes
the position of the blade.
SYSTEM OPERATION Refer to Figures 2 through 5 for voltage application
and hydraulic fluid flow for each snow plow function.
Each figure shows the components that are actuated
for each function.

SNOW
PLOW WIRING DIAGRAMS
Refer to Figures 6, 7 and 8 for wiring diagrams.
Refer to Specifications chart at the end of this
group.

SNOW PLOW MALFUNCTION DIAGNOSIS
AND

TESTS
Refer to the charts and illustrations for proper di­
agnosis.
SOLENOID VALVE COIL FUNCTIONAL TEST Test the coils for proper operation, according to the
following procedure. (1) Hold a screwdriver blade about 1/8 inch above
the nut on the coil to be tested. (2) Have a helper operate the control switch that
energizes the applicable coil.

CAUTION:
Do not connect an ohmmeter to a coil
when it is
applied.
This
can
cause
internal
damage
to the ohmmeter.
(3) If the coil is working, the electromagnetic ac­
tion will pull the screwdriver down to the retaining nut. If this does not occur, use an ohmmeter to check
the coil for continuity.

FRAME
AND
BUMPERS
13 -

TAN-

BLACK*
-o

ORANGE
WITH

WHITE

TRACER

SWITCH
I
RAISE

| AND j
!
LOWER
x

RED-
6 o

SWITCH

O
IGNITION SWITCH

ANGLE

TAN
LIGHT

'GREEN
ORANGE

WITH

WHITE
TRACER
FUSE

»
+
BATTERY

•o

SOLENOID SWITCH

•
MOTOR

ENERGIZED:
MOTOR
AND "B"
COIL
PRESSURE
RELIEF
"B"
SOLENOID

JUL.
'C"
SOLENOID
ANGLING CYLINDER

CSSE]
OPERATING
PRESSURE
EXHAUST
INTAKE
OR
DRAIN

METERED
FLOW

RB525

Fig.
2 Raise Blade—Voltage Application & Hydraulic Fluid Flow